Egg carton



M. BURGER May 4, 19,54

EGG CARTON 2 Sheets-Sheet 2 Filed May 11. 1948 INVENTOR. 'W MarfzCQ/ Patented May 4, 1954 UNITED saires ATiENT OFFICE EGG CARTON tion of Delaware Application May 11, 1948, Serial No. 26,331

7 Claims.

This invention is concerned with improvements in egg cartons of the type which when set up provide two rows of egg receiving compartments arranged on opposite sides of a medial double walled partition in conjunction with closing flaps which are adapted to be folded over the respective rows of compartments to provide separate covers for the rows of eggs.

More particularly, the invention relates to an improved carton which is formed of paperboard or similar material and which is characterized by a precut and scored blank of generally rectangular shape which blank is adapted to be formed into a carton body consisting of a double walled medial partition, bottom walls, side walls and cover aps, and a plurality of separate blanks which blanks are adapted to be positioned in interengaging relation in longitudinally spaced transversely aligned slots in the bottom walls and side walls of the body to provide ends and intermediate partitions.

It is a general object of the invention to provide in a carton of the type described improved features of construction which greatly facilitate the assembly of the carton components and which permit fabrication of the carton blanks in continuous manner on high speed cutting and scoring machines.

It is a further object of the invention to provide a carton of the type described wherein the blanks are also adapted to be readily cut in substantial quantities from a relatively thick stack. of blank forming sheets of paperboard material, by a single die cutting operation.

It is another object of the invention to provide in a carton of the type described an improved slot construction in the carton body which greatly facilitates the insertion of the cross wall members.

It is a further object of the invention to pro vide in a carton of the type described a cross wall `member incorporating an improved slot construction which is more readily cut when the Wall member is formed and which facilitates the assembly of the wall member with the medial partition member.

It is a still further object of the invention to provide a carton of the type described which is particularly adapted to be assembled and erected in a completely automatic set-up machine of the general character described in copending application Serial No. 39,688, filed July 20, 1948, now Patent No. 2,655,081.

These and other objects of the invention will be apparent to those skilled in this art from (Cl. 22g- 28) 2 a description of the carton and the modification thereof which are shown by way of illustration in the accompanying drawings, wherein:

Fig. 1 is a perspective view of a carton which is constructed in accordance with the principles of the invention, the carton being illustrated with the cover flaps in kopen position;

Fig. 2 is a partial side elevation of the carton with the cover flaps in closed position;

Fig. 3 is an end elevation of the cart-cn with the cover flaps in closed position;

Fig. 4 is a plan view of a cross-wall member with the medial partition indicated in section to illustrate the manner of inserting the medial partition in the central slot;

Fig. 5 is a plan view of a portion of a crosswall member, to an enlarged scale;

Fig. 6 is a plan view of a blank which has been cut and scored preparatory to forming the carto body;

Fig. '7 is a plan view of a portion of the body blank, to an enlarged scale;

Fig. 8 is a perspective view of a body blank folded about its medial score line and a crosswall member about to be inserted through the aligned pair of slots provided for it;

Fig. 9 is a partial plan view of a modified form of body forming blank; and

Fig. 10 is a plan view of a portion of the body forming blank of Fig. 9, to an enlarged scale.

The particular carton construction which is shown in the drawings for the purpose of illustrating the principles of this invention is the type which utilizes a blank It (Fig. G) which is formed into a double-walled medial partition, bottom walls, side walls, and cover members, in conjunction with a plurality of cross-wall members l I which provide end walls and intermediate partition walls.

The body forming blank Il! which is generally rectangular in shape, is provided with a central transverse score line I2 and parallel score lines I3, I4 and I5 arranged in spaced relation on opposite sides, respectively, of the central score line I2. The blank Ill is adapted to be folded about the score lines when the carton is erected to provide a carton body having in cross section the general form of the letter W.

The portions i6 of the blank between the medial score line l2 and the next adjacent score lines I3 form a double-walled longitudinal partition I'I (Fig-s. 1 to 3) and inside generally oblique bottom wall sections I8, the blank portions being adapted to bend -or bow generally about a line I9 intermediate thefscore lines l2 3 and I3. The portions 20 of the blank between the score lines I3 and I4 form upwardly and outwardly bowed longitudinal side walls.

The portions 2l of the blank, between the score lines I4 and I5, are adapted to fold about the score lines I4 to form top cover members, while the portions 22 and 23 of the blank between the score lines I5 and the ends of the blank 24 and 25, respectively, are adapted to fold about the score lines I5 to form securing fiaps for the cover members, the flap forming portion 23 being cut away at the corners on an oblique line 26 for a purpose which will be described.

The body forming blank I0 is provided with two rows of transversely spaced slots 21, each of which extends longitudinally on opposite sides of a transverse score line I3. The slots 21 are arranged so that when the blank I8 is folded upon itself about the medial line I2 the slots on one side will register with the corresponding slots on the other side for receiving the cross Wall members II. The slots 21 are spaced apart a sucient distance to accommodate a large size egg between each pair of adjacent cross walls I I. In the illustrated form there are seven slots in each row to provide a standard size carton having two longitudinal rows of six egg-receiving compartments separated by the double-walled partition I1, the end cross-wall members II con- I) stituting the end walls of the carton.

The slots 21 are particularly designed to facilitate insertion of the cross-wall members II and also to permit ready removal of waste stock in the cutting operation. Each slot 21 is cut in a zigzag pattern so that the Width of the waste stock removed is substantially greater than the 'unobstructed Width of the slot which corresponds approximately to the thickness of the cross-wall member II as shown particularly in Fig. '1. The edge of the blank material on each side of the slot is on an irregular or generally saw-toothed line with portions 28 forming pro-- jections extending toward the longitudinal center line of the slot and with alternate portions 29 defining recesses extending away from the center line, the portions 28 and 23 of opposite edges being opposite each other. As a result of this slot formation when a cross-wall member II is directed in edgewise position toward a slot aside sufficiently to permit insertion. The irregular edge offers less resistance to the passage of the cross-wall member, tending to urge it into proper alignment, and thus reduces the number of improperly assembled or damaged cartons when automatic set-up machines are employed. The width of the waste stock is sufficient to insure that the cutting knives will completely sever the material and that all waste stock will be completely removed during the cutting operation.

The blank II! is also provided with a series of circular cutouts or openings 3G along the central score line I2, each of the openings being in line with the slots 21 on opposite sides thereof and forming when the blank is folded semicircular notches for interlocking engagement with the cross-wall members II.

The cross-wall members II are preferably of the form shown in Fig. 4. Each of these members is of generally rectangular contour having an upper edge 3I and a bottom edge 32. The

bottom edge 32 is provided with rounded corners 33. The side edges extend vertically at 34 from the bottom and are notched or provided with inwardly and downwardly extending slots 35. The upper portion 36 at one side edge is recessed and slanted outwardly to a slight degree. The upper portion at the other side edge is cut away on an inwardly oblique line 31. The slots 35 terminate in a point at 38 to facilitate cutting and removal of the waste material.

The cross-fall members II are further characterized by a vertical slot 39 in the center region which extends downwardly from the upper edge 3I. This slot is of particular formation (Figs. 4 and 5). One side edge defining the slot 33 is provided with a lug formation 40 adjacent the upper edge 3i of the member which extends partly across the entrance of the slot. Below the lug 40 the edge of the material 4I extends in a generally vertical line with an intermediate portion 42 cut away to form a concave recess. The opposite edge of the slot 3S is cut along an oblique line 43 extending downwardly from the top edge to a point approximately opposite the recessed portion 42. The oblique edge 43 merges into a very short vertical portion 44. The bottom portion 45 is curved or irregular and terminates in a point 43 at the bottom. of the slot. The unobstructed width of the slot 39 is the distance between the vertical portions 4I of the one edge and the vertical portion 44 of the other edge. The recess `42 in the one edge of the slot facilitates the assembly of the wall members II with the double-walled longitudinal partition I1 by reducing the amount of bending or bowing required to insert the double-walled partition in the slot 39. The portion 44 of the other edge offers less resistance to the insertion of the partition wall I1 into the slot and will give sufciently to prevent jamming and consequent damage to the members where there is a relatively slight misalignment of the members during the assembling operation. By cutting the slot 33 as shown the width of the waste material is increased substantially and its removal in the cutting operation is greatly facilitated particularly with the bottom of the slot terminating in the sharp point at 46.

The operation of assembling the cross-wall members II with the body forming blank I0 as illustrated in Fig. 8 may be followed in setting up the carton by hand. )It will be understood that when the carton is assembled and set up by the mechanism disclosed in the copending application Serial No. 39,688, the bottom forming blank It) will be positioned on a mandrel with the medial fold line I2 extending generally downwardly and the cross-wall members II will be fed simulta' neously in reverse cdgewise position for insertion in the slots 21. In the machine set up the two halves of the body forming blank I0 will not be in superimposed relation as illustrated in Fig. 6 but the slots 21 on opposite sides of the medial line l2 will be in registry. In setting up the carton by hand the cross-wall members II may be .inserted in the Slots 21, the length of the slots 21 exceeding the vertical dimension of the crosswall members. The cross-wall members are then' shifted lengthwise of the slots 21 so as to bring the double-walled partition member I1 down into engagement with the lower end of the slots 3S (Figs. 4 and 5). During this movement the double-walled partition I1 will slide into the slot 39 without any appreciable bending due to the clearance recess 42 and to the tendency of the portion 44 of theopposite side yedge pf the .slot to bend or spring sidewise out of the 'way of 'the member Il. When the members are-:in interengaged relation the lug formation-'40 extends through the semi-circular notch 3E while the double thickness of material forming the partition wall Il is held in interlocked'relation by vengagement with the edge portions 4I on one side thereof and the edge portion 44 on the other side thereof.

After the cross-wall .members I i have been interlocked with the longitudinal partition I1 the halves of the blank are folded up land around the ends 34 of the cross members -II to project the rounded corners 33 through the slots -21 on the respective sides of the carton and the ends of the slots 2 are engaged in the slots 35 in the ends 34 of the cross-wall members. In this position the carton may be lled with the eggs after which the cover members 2l are folded about the score lines I t and their iiaps 22 Vand 2'3 :are folded about the score lines I5 to bring the cover Amembers 2| into overlying relation to the rows of lcompartments, the flaps and 23 being tucked 'down into the `slots 39 as shown in Fig. 3 to complete the closing of the carton. When the carton is placed on a supporting surface it rests on the folds at the score lines .I3 and the bottom edges 32 of the cross-wall members.

In assembling and setting up `t-he carton by automatic machinery such as shown 'in the copending application Serial No. 39,688 the Vbody forming blank is folded about the medial line I2 and placed in a stack from which the blanks are fed one by one to a supporting mandrel in which they are opened up by a folding head and held in position for the insertion of the cross-wall members II.

To permit the halves of the blank to be separated as the blank is fed to the mandrel the corners of the flap 25 have been cut away along an oblique line 2S so that the half of the carbon blank which extends between the line I2 andthe end edge 25 may be freed of side guide members to permit it to swing upwardly away from the other half of the blank as the mandrel is turned to position it for the operation of the folding head.

The cross-wall members I I are cutaway at the one upper corner along the line 31 to facilitate the assembly of these members with the body forming blank in the automatic set-up machine. The cross-wall members II are simultaneously positioned for insertion in the slots 21 with the members ii in edgewise relation and resting on the upper edge 3i. As the members II are inserted in the slots 2i they are moved forwardly and downwardly away from the guide channels in which they are delivered to the folding mandrel. The oblique corner construction insures that the cross members II will clear the guide channels and will not be obstructed in their movement into interlocking relation with the longitudinal partition wall.

A modification of the body forming blank is illustrated in Figs. 9 and 10. The blank 50 is identical with the blank Iil in every respect except the slots 5I which differ in formation from the slots 2l in the blank I6. Referring more particularly to Fig. l0, the side edges of the slots are of generally saw-toothed formation having inwardly extending portions 52 which are in opposed relation and separated approximately a width corresponding to the thickness of the material of the cross member indicated at 53. The

inwardlyientending portions 52 are separated yby outwardly extending recess forming portions 54. The v`effect-of this configuration of the slot 5I is toprovide an unobstructed passageway of sufcient width to `accommodate the cross-wall member v53 `and to provide a line of projecting or inwardly extending portions 52 on each side thereof which offer yless resistance to the movement of the cross-wall `member 53 .into the slot than would be provided if the side edges were made straight and regular. The .irregular edge formation provides in effect a slot which is substantially wider than the :thickness of the cross-wall members 53sottratthecross-wall member 53 will be guided through the slot leven though it is somewhat out of alignment with the center line of the slot. The slot 51 vis `terminated at the end in a relatively sharp point. The increased width of the waste material and the pointed end construction both facilitate cutting and removal of the waste material. The slots y5I are shown in Fig. 10 with straight line portions vbetween the extending portions 52 and the recess portions 54 but the material may be cut along a curved line as shown in the outerslots 55 in Fig. 9, This provides less resistance in the inwardly projection portions.

In describing the body forming blanks, Atransverse score lines have been referred to where a denite `bend or fold line is desired. The blank material `may be weakened by other means than scoring in order to localize the bending of the material about the desired line.

While spec-ic details of construction and particular materials are referred to in describing the illustrated forms of the carton, it will be understood that other details of construction and other materials may be resorted to within the spirit of the invention.

I claim:

1. In a collapsible cellular carton, foldable trough members arranged side by side and having oppositely inclined bottom sections meeting ina ridge centrally of the carton, said bottom sectionsbeing provided with slots having sawtooth-like opposed edges, a plurality of cross wall members `each having side and intermediate slots, .said cross-wall members being adapted for insertion through the slots in said bottom sections, and each Vcross wall being provided with a lug formation partially obstructing the entrance to the intermediate slot, said intermediate slot being adapted to receive the central ridge and said lug formation being adapted to interlock with said central ridge, and said opposed edges. defining the slots in said bottom sections having inner portions spaced from each other afdistance which is less than the width of the slots 'and approximately the same as the thickness vof the material of said cross-wail members whereby to engage with the faces of said cross wall members at a plurality of points intermediate the top and bottom edges thereof and restrict movement of said cross-wall members laterally in said slots.

2. In a collapsible cellular carton as recited in claim 1 wherein the saw-tooth-like edges defining the slots in the bottom sections of the carton have the innermost portions along one edge thereof in aligned and opposed relation to the innermost portions along the opposite edge thereof.

3. In a collapsible cellular carton as recited in claim 1 wherein the saw-tooth-like edges defining the slots in the bottom sections of the carton have the innermost portions along one edge thereof in staggered relation to the innermost portions along the opposite edge thereof.

4. An egg carton which comprises a body forming blank having plural sets of aligned slots, the

lank being adapted to be folded upon itself along a line between two sets of slots to form a longitudinal partition wall, and a plurality of cross walls adapted for insertion through the slots of the blank, each of said cross walls having a slot extending inwardly from the top edge, each slot in said cross walls being characterized by one edge thereof having a lug formation projecting partly across the entrance to the slot and said edge extending inwardly a predetermined distance therefrom and having a concave portion intermediate its ends, the opposite edge of said slot having its top portion extending upwardly and outwardly on an oblique line to provide a narod entrance for the slot, said opposite edge having a straight portion opposite the concave portion of said other edge and having its lower portion curving downwardly andY then inwardly to join the first mentioned edge, the unobstructed space between the straight portions of the edges of said slot being oi a width approximately the same as the thickness of said longitudinal partition wall.

5. A carton formed of paperboard or similar material which is characterized by a body forming blank of generally rectangular shape which is adapted to be folded to form a double-walled medial partition, bottom walls, side walls and cover flaps and by a plurality of separate crosswall forming members which are adapted to be positioned in interengaging relation in longitudinally spaced transversely aligned slots in the body blank, the opposed edges of the material defining the transverse slots being cut on irregular lines to provide in the bottom walls a plurality of inwardly projecting members the innermost portions of which are spaced'to define a straight unobstructed passageway which is approximately a width corresponding to the thickness oi the cross-wall members and which extends substantially the full length of said slots, said inwardly projecting members being spaced to engage opposite faces of said cross-wall members at a plurality of points spaced intermediate the top and bottom edges thereof.

6. A carton formed of paperboard or similar material which is characterized by a body blank of generally rectangular shape which is folded to form a double-walled medial partition, bottom walls, side walls and cover naps and which is further characterized by a plurality oi separate cross wall blanks which are positioned in interengaging relation in longitudinally spaced transversely aligned slots in the bottom and side walls, the edges of the blank material deiining the transverse slots being formed to provide a series of inwardly projecting portions spaced lengthwise of the slots and having innermost extremities which are adapted to flex whereby to afford ready passage of the cross wall blanks during assembly of said blanks by movement thereof in a lateral direction into said slots and said innermost extremities of said projecting portions on one side of the slots being spaced from the corresponding portions on the other side of the slots a distance corresponding approximately to the thickness of the material of the crosswall blanks whereby to prevent movement of the cross wall blanks throughout their depth in a lateral direction relative to the slots.

7. An egg receiving carton which comprises a body forming blank having a plurality of sets of aligned slots, said blank being adapted to be folded upon itself along a line between two sets of slots to form along said line a double-walled longitudinal partition member and a plurality of generally rectangular cross wall members adapted for insertion through aligned slots in the body blank, each cross wall member having a slot extending inwardly of the top edge, said slot in the cross wall member having a flaring entrance and a lug formation projecting from one edge of said slot partly across the entrance thereof, and said one edge extending inwardly a predetermined distance therefrom and a concave portion spaced inwardly from said lug formation and spaced outwardly of the bottom of said slot providing lateral clearance for the lower edge of the double-walled partition member to facilitate entrance into the slot of said doublewalled partition member, the opposite edge of said slot having its top portion extending upwardly and outwardly on an oblique line to provide a flared entrance for the slot, said opposite edge having a straight portion opposite the concave portion of the other edge, the unobstructed space between the straight portion of said opposite edge and the portions of said one edge which adjoin the concave portion thereof being of a width approximately the same as the thickness of said longitudinal partition wall.

References Cited in the le of this patent UNITED STATES PATENTS Number Name Date Re. 19,143 Benoit Apr. 2li, 1934 606,913 Bower July 5, 1398 1,937,603 Swager Dec. 5, 1933 1,978,719 Parnin Oct. 30, 1934 FOREIGN PATENTS Number Country Date 294,700 Great Britain Aug. 2, 1928 391,348 Great Britain Apr. 27, 1933 

